CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No.

62/857,113, filed June 4, 2019, which is hereby incorporated herein in its entirety.

FIELD

[0002] This disclosure relates to heat exchangers and, more specifically, to heat exchangers having tubular membranes that facilitate heat transfer between two fluids.

BACKGROUND

[0003] Heat exchangers (HX) come in a wide variety of configurations and are used in a wide variety of applications. In one approach, referred to as tubular membrane HX, tubes are inserted in tube sheets and sealed to the tube sheet using a number of methods including welding, rolling, braising and gluing (for plastic tubular membrane HX). Another approach involves potting all of the tubes at once with a tube sheet rather than gluing tubes one by one. In yet another approach, tubes together are bundled and compressed mechanically to seal the assembly.

[0004] Sealing membrane tubes can be a challenge due to the small size and large number of tubes. Further, potting a membrane tube in a tube sheet can be a challenge due to poor adhesion of the potting to the tube. Additionally, with inconsistent and/or flexible tubes, uneven gaps between tubes and tube sheets can create leaks.

[0005] Additionally, water flow rates for tubular membrane HX may be limited by sealant issues resulting in lowering the heat and mass transfer properties for the tubular membrane HX. Membrane tube-to-tube sheet seal strength, not tube and tube sheet strength, may be the limiting factor in working pressure of the heat and mass exchangers for these types of applications which in turn limits the versatility and applicability of the tubular membrane HX.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a schematic view of a heat exchanger system including tubular membrane heat exchanger assemblies;

[0007] FIG. 2 is a perspective view of one of the tubular membrane heat exchanger assemblies of FIG. 1;

[0008] FIG. 3 is a cross-sectional view of a portion of the tubular membrane heat exchanger assembly of FIG. 2 showing tubular membranes, header bodies, fittings connecting the tubular membranes to the headers, and a spacer plate separating the tubular membranes;

[0009] FIG. 4 is an exploded, perspective view of an end portion of one of the tubular membranes of FIG. 3 showing the tubular membrane, a fitting, a rubber band that connects the tubular membrane to the header body;

[0010] FIG. 5 is a cross-sectional view of a tubular membrane assembly including one of the tubular membranes of FIG. 3 showing potting embedding an end portion of the tubular membrane, the rubber band, and an outer surface of the header body;

[0011] FIG. 6 is a cross-sectional view of another tubular membrane heat exchanger assembly without a spacer plate to separate the tubular membranes;

[0012] FIG. 7 is a perspective view of a header showing a plate portion of the header, openings in the plate portion for receiving tubular membranes, and a curb extending about the plate portion to retain liquid potting when the liquid potting is poured onto the header;

[0013] FIG. 8 is a view similar to FIG. 7 showing a tubular membrane having been advanced into one of the openings of the header plate portion;

[0014] FIG. 9 is a perspective view of a header showing tubular membranes inserted into openings of a plate portion of the header before potting has been applied to the header;

[0015] FIG. 10 is an exploded, perspective view of a tubular membrane, a fitting, and a plate portion of a header;

[0016] FIG. 11 is a cross-sectional view of the tubular membrane, fitting, and header plate portion of FIG. 10 assembled and having potting applied to opposite sides of the header plate portion; and

[0017] FIG. 12 is a cross-sectional view of a header having a unitary fitting and header body. DETAILED DESCRIPTION

[0018] In one aspect, a tubular membrane assembly is provided for a heat exchanger. The tubular membrane assembly includes a header having a header body, a tubular membrane, and a fitting connecting the tubular membrane to the header body. The fitting is configured to form a fluid tight connection between the fitting and the tubular membrane. The tubular membrane assembly further includes potting of the header keeping the tubular membrane connected to the fitting. The tubular membrane assembly provides a secure connection between the header body and the tubular membrane, which may be flexible and relatively small in cross-section, and facilitates the use of fluid pressures in excess of 5 pounds per square inch (psi), such as in the range of approximately 10 psi to approximately 20 psi, or greater than 20 psi such as approximately 50 psi or greater. The durability provided by the tubular membrane assembly permits a heat exchanger to be provided with variable spacing between the tubular membranes of the heat exchanger. Variable spacing between tubular membranes facilitates the configuration of the heat exchanger to be optimized for a particular application.

[0019] In another aspect of the present disclosure, a heat exchanger is provided that includes at least one tubular membrane heat exchanger and a fan assembly operable to generate airflow relative to the at least one tubular membrane heat exchanger. The heat exchanger further includes a pump operable to pump fluid. The at least one tubular membrane heat exchanger is configured to receive the fluid and includes an inlet header, an outlet header, a plurality of tubular membranes, and fittings coupling the tubular membranes to the inlet and outlet headers. In one embodiment, the tubular membranes each have a side wall extending about a lumen of the tubular membrane. The tubular membranes provide a high ratio of effective heat and mass transfer surface area per heat and mass exchanger unit volume to provide efficient heat transfer between a fluid in the lumens of the tubular membranes and a fluid outside of the tubular membranes.

[0020] In one embodiment, the side walls of the tubular membranes are made of a material that is gas-permeable and liquid-impermeable. For example, the fluid may include a mixture of water and water vapor and the side walls of the tubular membrane permit water vapor to permeate out of the tubular membranes. The removal of the higher-energy water vapor reduces the temperature of the fluid flow in the tubular membranes. Further, the airflow generated by the fan assembly removes the water vapor from outer surfaces of the tubular membranes.

[0021] In one embodiment, the at least one tubular membrane heat exchanger may be removable from the heat exchanger to facilitate assembly of the heat exchanger as well as permit repair or replacement of the tubular membrane heat exchanger assembly.

[0022] Regarding FIG. 1, a heat exchanger system 10 is provided that includes a heat exchanger 11 that receives heat, such as heat from inside of a building, and transfers the heat to a fluid such as water or a water/glycol mixture. The fluid may include liquid and gas, the proportions of which may vary as the working fluid travels throughout the heat exchanger system 10. The heat exchanger system 10 includes a pump 12 configured to pump the fluid from the heat exchanger 11 to a heat exchanger 40. The heat exchanger 40 includes one or more heat exchanger cassettes, such as tubular membrane heat exchangers 50. The tubular membrane heat exchanger 50 are releasably or permanently connected to an inlet manifold 52 and an outlet manifold 54. In another approach, the heat exchanger 40 may receive heat and transfer the heat to the fluid, while the heat exchanger 11 removes heat from the fluid.

[0023] Regarding FIG. 2, each tubular membrane heat exchanger 50 includes an inlet header 70 that receives the fluid from the inlet manifold 52, one or more tubular membranes 74 through which the fluid travels, and an outlet header 72 that collects the fluid from the tubular membranes 74. The tubular membranes 74 facilitate heat and/or mass transfer between a first fluid within the tubular membranes 74 and a second fluid outside of the tubular membranes 74. As one example, the tubular membranes 74 may be made of a gas- permeable material that is also liquid-impermeable. The tubular membranes 74 receive fluid including a mixture of liquid and gas that has been heated by the heat exchanger 11. The tubular membranes 74 permit the gas, such as vapor, that has been heated by the heat exchanger 11 to travel out of the tubular membranes 74. As an example, the fluid entering the tubular membranes 74 may be a mixture of water and water vapor. In another approach, the fluid may be completely gas upon reaching the tubular membranes 74 and may exit the outlet header 72 as a liquid or a gas/liquid mixture. [0024] The tubular membranes 74 may be made of, for example, one or more polymers such as polypropylene (PP), polydimethylsiloxane (PDMS) or polytetrafluoroethylene (PTFE). The tubular membranes 74 may be porous and include openings in the nanometer diameter range to facilitate heat and/or mass transfer. The tubular membranes 74 may be flexible and relatively flimsy which makes gripping the tubular membranes 74 difficult to secure to another component. For example, the tubular membranes 74 may be stiff enough to be placed vertically on a surface and retain their shape, but any external pressure makes the tubular membranes 74 bend and/or twist.

[0025] Regarding FIG. 1, the heat exchanger system 10 includes a fan assembly 14 having one or more fans 16 and one or more motors 18. The fan assembly 14 is configured to generate airflow relative to the tubular membranes 74, such as in direction 75 along the lengths of the tubular membranes 74, and/or in directions transverse to the lengths of the tubular membranes 74. The airflow may assist in removing the gas from outer surfaces 91 (see FIG. 3) of the tubular membranes 74. The fluid may be water, as mentioned above, and pure water vapor may permeate through the tubular membranes 74 while contaminants such as debris, scale, and organisms remain inside of the tubular membranes 74. Further, the tubular membranes 74 inhibit exterior contaminants from entering the tubular membranes

74.

[0026] Regarding FIGS. 1 and 2, the outlet header 72 of each tubular membrane assembly 50 directs the fluid to the outlet manifold 54. The heat exchanger system 10 includes a pump 30 configured to pump the fluid from the outlet manifold 54 to the heat exchanger 11 and throughout the heat exchanger system 10. The pump 30 may generate a gauge pressure of the fluid at the inlet header 70 in the range of approximately zero pounds per square inch (psi) to approximately 50 psi such as 5 psi or higher, 10 psi or higher, or 15 psi or higher, 20 psi or higher, 30 psi or higher, or 40 psi or higher. The heat exchanger system 10 may further include a fluid supply 60 that adds fluid, such as liquid, gas, or a liquid/gas mixture, to the system 10 to compensate for the gas permeating out of the tubular membranes 74.

[0027] Regarding FIG. 3, the tubular membranes 74 may each include an internal passageway, such as a lumen 76, and a side wall 78 extending thereabout The lumen 76 may have an inner diameter in the range of approximately 0.1 inches to approximately 0.5 inches, such as 0.25 inches or 0.125 inches. The side wall 78 may have a thickness in the range of 1 micron to approximately 200 microns, such as approximately 1 micron to approximately 5 microns, such as approximately 5 microns to approximately 10 microns, such as approximately 10 microns to approximately 15 microns, such as approximately 15 microns to approximately 50 microns, such as approximately 30 microns, such as approximately 50 microns to approximately 75 microns, such as approximately 150 microns to approximately 200 microns. As further examples, the tubular membranes 74 may have an inner diameter less than 5 millimeters (mm), approximately 5 mm, or greater than 5 mm.

[0028] The tubular membranes 74 may be flexible and the tubular membrane heat exchanger 50 may include a support for each of the tubular membranes 74 that resists lateral movement, bending and ballooning of the tubular membrane 74. The support may extend a majority of, such as greater than 50%, 60%, 70%, 80%, 90% or substantially the entire length of the tubular membrane 74. In one embodiment, the support may include a braided sleeve surrounding the tubular membrane 74 and extending substantially the entire length of the tubular membrane 74. The braided sleeve may be made of a woven plastic or metal material that inhibits bending of the tubular membrane 74. An example braided sleeve 174 is discussed below with respect to FIG. 9. Other embodiments of the supports may include rods or other elongate guides. Yet other embodiments of the supports may include coils about the tubular membranes 74.

[0029] Regarding FIG. 3, the inlet header 70 has a header body 71 including a plate portion 82 with openings 80. The fluid in the heat exchanger system 10 may travel through the openings 80 in the plate portion 82 of the inlet header 70 generally in direction 84 and into the lumen 76 of the tubular membrane 74. The side wall 78 of the tubular membrane 74 permits gas of the fluid, such as water vapor in a fluid including water vapor and water, to permeate outward through the side wall 78 roughly in direction 86 and into contact with the air flow generated by the fan assembly 14. The liquid of the flow, such as the water, travels through the lumen 76 of the tubular membrane 74 and into the outlet header 72 via openings 90 in a plate portion 83 of the outlet header 72. [0030] Regarding FIG. 2, the tubular membrane heat exchanger 50 have a modular configuration that permits the tubular membrane heat exchanger 50 to be individually connected to and removed from the heat exchanger system 40. The module nature of the tubular membrane heat exchanger 50 also permits the capacity of the direct heat exchanger 40 to be adjusted by adding or removing tubular membrane heat exchangers 50 and making associated changes to the volume of fluid in the system 10, capacity of the heat exchanger 11, and/or flow rate of the pump 30 as appropriate.

[0031] The tubular membrane heat exchanger 50 may include a frame 92 supporting the inlet and outlet headers 70, 72, the tubular membranes 74, and the spacers 96. The frame 92 has an opening 94 that permits air flow along and between the tubular membranes 74 to facilitate dissipation of the heated gas that has permeated through the side walls 76 of the tubular membranes 76. Regarding FIG. 3, the spacers 96 include openings 98 that receive the tubular membranes 74. The spacers 96 resist lateral shifting and bending of the tubular membranes 74 upon the tubular membranes 74 receiving pressurized fluid. The spacers 96 may also keep the tubular membranes 74 in a generally straight, parallel orientation while the tubular membranes are potted, as discussed below, which facilitates production of a gap-free connection between the potting material and the tubular membranes 74. The number and thickness of the spacers 96 may be selected so that the spacers 96 operate as supports in lieu of the sleeves 174.

[0032] Regarding FIG. 4, the tubular membrane 74 has an end portion 100 that is connected to the plate portion 82 of the inlet header 70 via a connector, such as a fitting 102. The tubular membrane 74 is connected to the plate portion 83 of the outlet header 72 via a similar fitting 102. The fitting 102 has a nipple portion 104, a base portion 108, and a through opening that permits fluid flow through the fitting.

[0033] To assemble the tubular membrane 74 with the header plate portion 82, the nipple portion 104 is advanced in direction 106 into the lumen 76 of the tubular membrane 74. The assembled tubular membrane 74 and fitting 102 are shifted in direction 106 to seat the base portion 108 of the fitting 102 in the opening 80 of the plate portion 82. A retainer, such as a rubber band 110, may be secured to the end portion 100 of the tubular membrane 74 to keep the end portion 100 secured to the nipple portion 104 of the fitting 102. For example, the rubber band 110 may be shifted in direction 112 along the tubular membrane 74 until reaching the end portion 100. The rubber band 110 applies a compressive force on the tubular membrane 74 that holds the tubular membrane 74 tightly against the nipple portion 104 of the fitting 102. In another embodiment, the retainer may include a zip tie or a spring-biased mechanical clamp as some examples. Other examples of the retainer may include a gasket, an expanding-foam material, glue, or a combination thereof.

[0034] Regarding FIG. 5, the tubular membrane 74, fitting 102, and rubber band 110 have been assembled to the plate portion 82. The inlet header 70 includes potting 120 that has been applied to a surface 122 of the header plate portion 82. The potting 120 may include an epoxy potting or an ultraviolet-curable silicone potting as some examples. The potting 120 embeds the end portion 100 of the tubular membrane 74 and the rubber band 110 within the potting 120 and forms a mechanical bond between the components. In some embodiments, the potting 120 forms a chemical bond with the tubular membrane 74 to further resist movement of the tubular membrane 74 relative to the potting 120.

[0035] The nipple portion 104 forms an interference fit with an inner surface 141 of the side wall 78 of the tubular membrane 74 to form a fluid-tight seal. The fitting 102 has a central axis 79 and may have a varying width taken transverse to the longitudinal axis 79 to facilitate sealing of the tubular membrane 74 and mechanical locking of the fitting 102 to the plate portion 82. In one example, the nipple portion 104 has a frustoconical outer surface 140 sized to permit the nipple portion 104 to be advanced at least partially into the lumen 76 of the tubular membrane 74 and form a fluid tight seal with the inner surface 141 of the side wall 78 of the tubular membrane 74. The fitting base portion 108 has a frustoconical surface 130 that mates with a corresponding frustoconical surface 132 of the opening 80 of the plate portion 82. The surfaces 130, 132 form a friction fit that inhibits the potting material 120 from seeping between the plate portion 82 and the fitting 102 before the potting 120 has cured. The mating engagement between surfaces 130, 132 also inhibits pull-though of the fitting 102 upon pressurization of the fluid in the system 10.

[0036] The potting 120 maintains the seal between the tubular membrane 74 and the fitting 102. As one example, the potting 120 may chemically bond with the material of the tubular membrane 74 and, once cured, inhibits movement of the tubular membrane 74. The potting 120 may also chemically bond with the bodies 82 of the inlet and outlet headers 70, 72 such as in embodiments wherein the bodies 82 are made of a polymer. In another

embodiment, the potting 120 may not chemically bond with the tubular membrane 74 but the presence of the cured potting inhibits movement and/or expansion of the portion of the tubular membrane 74 engaged with the nipple portion 104 of the fitting 102. By maintaining the seal between the tubular membrane 74 and the fitting 102, the potting 120 keeps fluid from seeping between an end 103 of the tubular membrane 74 and the nipple portion 104 and expanding the end 103 due to contact with the fluid. In some embodiments, the material of the tubular membrane 74 expands when contacted by the fluid such that the contact of the potting 120 against the tubular membrane 74 keeps the tubular membrane 74 sealed to the nipple portion 104 upstream of the end 103 so the end 103 stays free of fluid and secured to the fitting 102. The potting 120 thereby keeps fluid within the lumen 76 of the tubular membrane 74 and away from the end 103 of the tubular membrane 74.

[0037] Regarding FIG. 6, in some embodiments, the tubular membrane heat exchanger assembly 50 may be provided without the spacers 96. In this form, the tubular membranes 74 extend from the inlet header 70 to the outlet header 72 without the spacers 96.

[0038] Regarding FIG. 7, the inlet header 70 is shown without the tubular membranes 74 attached. Although the following discussion refers to the inlet header 70, the outlet header 72 may have a similar construction. The inlet header 70 includes a curb 150 upstanding from the periphery of the plate portion 82. The curb 150 and plate portion 82 form a recess 152 for receiving liquid potting material and keeping the liquid potting material in contact with the tubular membranes 74 until the potting material has cured and solidified.

[0039] Regarding FIG. 8, a tubular membrane 74 is shown advanced into one of the openings 80 of the plate portion 82. The inlet header 70 includes one or more side wall portions 154 that extend in an opposite direction from the curb 150 and form an interior compartment of the inlet header 70. The interior compartment 156 may be a volume that receives the fluid which the inlet header 70 then directs into the tubular membranes 74.

[0040] In some embodiments, the headers 70, 72 and fittings 102 are made of the same or different metallic and/or polymer-based materials. The tubular membrane heat exchanger 50 may have one or more components made by additive or subtractive manufacturing approaches, such as 3D printing or milling. As further examples, one or more components of the tubular membrane heat exchanger 50 may be molded.

[0041] Regarding FIG. 9, a portion of another tubular membrane heat exchanger 169 is provided that includes tubular membranes 170 and a header 172. FIG. 9 shows the portion of the tubular membrane heat exchanger 169 before the potting material is applied to a plate portion 182 of the header 172.

[0042] The tubular membrane heat exchanger 169 includes sleeves 174 on the outside of and supporting the tubular membranes 170. The sleeves 174 may have a woven structure with openings that permit airflow through sleeves 174. In one example, the sleeves 174 include a metallic mesh that resists deformation of the tubular membranes 170 while having openings that permit airflow into contact with the tubular membranes 170 and removal of the permeated gas near the exterior of the tubular membranes 170.

[0043] The tubular membrane heat exchanger 169 includes rubber bands 176 securing the sleeves 174 and tubular membranes 170 therein to fittings that connect the tubular membranes 170 to the header 172. In one embodiment, the fittings resemble the fittings 102 discussed above. The header 172 includes a curb 180 extending around a periphery of the plate portion 182 of the header 172. The header 172 further includes a barrier wall 184 that separates a recess 186 of the header 172 into two halves. The barrier wall 184 permits one half of the recess 186 at a time to be filled with potting material. This may make manufacturing easier because the recess 186 to be filled with potting material with a sequence of pours of potting material.

[0044] Regarding FIG. 10, a tubular membrane 200 is provided that connects to a header plate portion 202 via a fitting 204. In some embodiments, a sleeve may be provided around the tubular membrane 200 to support the tubular membrane 200 as discussed above with respect to FIG. 9. The fitting 204 has an end portion 208 that is sized to tightly fit into an end portion 206 of the tubular membrane 206. In one embodiment, the fitting 204 is a tube having an annular side wall 210 and a cylindrical outer surface 212 that engages a surface 223 of the opening 222. The cylindrical outer surface 212 has an outer diameter and the surface 223 has an inner diameter that are sized to form a tight fit between the fitting 204 and the plate portion 202 which inhibits liquid potting from seeping between the fitting 204 and the plate portion 202 when the potting is poured onto the plate portion 202. Further, the outer diameter of outer surface 212 may be within ± 1% of an inner diameter of the tubular membrane 200. The tubular membrane 200 and fitting 204 may be configured to form a fluid-tight seal therebetween and the potting 120 reinforces the fluid-tight seal to resist pressurized fluid. In other embodiments, the tubular membrane 200 and fitting 204 may form a fluid-tight seal therebetween after the potting 120 has cured.

[0045] With reference to FIGS. 10 and 11, the tubular membrane 200 is connected to the header plate portion 202 by advancing the end portion 208 of the fitting 204 into a lumen 214 of the tubular membrane 200. The fitting 204 may engage the tubular membrane 200 and form a fluid-tight connection therebetween. The connecting may further include advancing an opposite end portion 220 of the fitting 204 into an opening 222 of the header plate portion 202. The end portion 220 of the fitting 204 is advanced so that the end portion 220 protrudes outward from a surface 224 of the header plate portion 202. The tubular membrane 200 has an end 226 that is positioned against or near an opposite surface 228 of the header plate portion 202.

[0046] To maintain the seal between the tubular membrane 200 and fitting 204 upon the tubular membrane 200 receiving pressurized fluid, potting 230 is applied to the surface 228 of the header plate portion 202 and into contact with the tubular membrane 200. Potting 232 is also applied to the surface 224 of the header plate portion 202. The potting 232 connects to the end portion 220 of the fitting 204 to resist pull-through of the fitting 204 in direction 240. The potting 230, 232 may be made of the same or different potting materials. The potting 230, 232 may each have a depth in the range of 0.1 inches to 1 inch, such as approximately 0.25 inches or less. In one embodiment, the fitting 204 includes a thin- walled stainless steel tube.

[0047] Regarding FIG. 12, a header 250 may be provided that includes a header body 251 including a fitting 252 and a header plate portion 254. The header body 251 has a unitary, one-piece construction and may be made of metallic or polymer materials. The fitting 252 may include a side wall 256 having a circular cross-section such that the side wall 256 has a cylindrical outer surface 258.

[0048] A tubular membrane 260 connects to the fitting 252 in a manner similar to the tubular membrane 200 being connected to the fitting 204 discussed above. The header 250 includes potting 262 that secures an end portion 264 of the tubular membrane 260 to the fitting 252. In one embodiment, the tubular membrane 260 has an end 266 that is contacting or near a surface 268 of the header plate portion 254. The fitting 252 has an opening 270 in communication with a lumen 272 of the tubular membrane 260 to permit fluid to travel between the tubular membrane 260 and the header 250.

[0049] The tubular membranes and fittings discussed above may have a circular cross- section in some embodiments. In other embodiments, the tubular membranes and fittings may have a variety of cross-sectional shapes including, but not limited to, obround, elliptical, teardrop, triangular, square, rectangular, or a combination thereof.

[0050] Uses of singular terms such as“a,”“an,” are intended to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context The terms“comprising,”“having,”“including,” and“containing” are to be construed as open- ended terms. It is intended that the phrase“at least one of’ as used herein be interpreted in the disjunctive sense. For example, the phrase“at least one of A and B” is intended to encompass A, B, or both A and B.

[0051] While there have been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended for the present invention to cover all those changes and modifications which fall within the scope of the appended claims.